Forming and conveying of baked confection shells

ABSTRACT

A method of forming and conveying hot baked shells is disclosed. Confectionary discs are picked up after baking and fed in succession to a rotary wheel which folds the disc into taco shapes. A fixed rail receives the folded shell so that the shells hang therefrom. An endless belt, coextensive with the support rail, holds the formed shells to the rail and frictionally drives the shells freely sliding therealong. In the embodiment disclosed, the support rail and support device are tubular and fluid flows therethrough to cool and harden the formed shells. The traveling folded shells are subjected to an oil spray which tends to make the shells remain crisp and generally impervious to moisture from a subsequently applied filling.

This is a division of application Ser. No. 06/600,764, filed Apr. 16,1984 now U.S. Pat. No. 4,534,722.

BACKGROUND AND SUMMARY OF THE INVENTION

This invention relates to forming and conveying of baked confectionshells.

A recent development in frozen confections is the provision of asandwich-like item which comprises a sugar shell shaped like a tacoshell and which is filled with ice cream or the like and suitably coatedwith toppling, chips etc. if desired. While the shell resembles a tacoshell made from a lap folded tortilla, it actually is constituted ofdifferent ingredients such as those used in a sugar based cookie cone.Such cones are often made by baking a plurality of flat discs insuccession in a suitable baking machine and then forming each bakeddisc, while in relatively soft condition, on rotating ice cream coneshaped dies.

It is an object of the present invention to provide a shell forming andconveying machine for use at the discharge of a baking machine to createtaco-like confection shells from baked discs.

It is a further object of the invention to form the discs into taco-likeshape and then convey them downstream in a simple manner for furtherprocessing.

It is yet another object of the invention to control and fix the shapeof the formed shells during conveying, and to treat the shells so thatthey remain crisp when subsequently filled with ice cream or the like.

It is an additional object to at least partially prevent the conveyingmechanism from being adversely affected by the high temperature of thebaked shells.

In accordance with the various aspects of the invention, a machine isprovided which includes a pick-up station adapted to receive flatconfection discs from a baking machine, and feed them in succession to arotary wheel at a forming station to lap fold the discs into taco shape.A fixed elongated support rail having a curved upper surface extendsgenerally the length of the conveyor and receives the folded shellsthereover so that the shells hang therefrom. An endless belt iscoextensive with the support rail and biasingly holds the formed shellsto the rail and frictionally drives the shell freely slidinglytherealong.

A pair of shell leg receiving channels are disposed beneath the supportrail, with the channels formed by inner and outer generally parallelwalls coextensive with the rail. The inner walls are defined by asupport device beneath the rail while the outer walls are formed byplates which are transversely adjustable to thereby control the channelwidth and shell leg angle. In the embodiment disclosed, the support railand support device are tubular and fluid flows therethrough to cool andharden the formed shells.

The traveling folded shells are subjected to an oil spray which tends tomake the shells remain crisp and generally impervious to moisture from asubsequently applied filling.

Furthermore, the drive belt is cooled adjacent the shell discharge tocounteract belt expansion caused by engagement with the hot bakedshells.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate the best mode presentlycontemplated by the inventors for carrying out the invention.

In the drawings:

FIG. 1 is a schematic side elevation of a forming and conveying machineadapted to incorporate the various aspects of the invention;

FIG. 2 is an enlarged fragmentary showing of the shell pick-up stationadjacent the discharge end of the baking machine;

FIG. 3 is a plan view of the shell forming wheel, taken on line 3--3 ofFIG. 1;

FIG. 4 is a front end view of the wheel taken on line 4--4 of FIG. 1;

FIG. 5 is a transverse section through the conveyor taken on line 5--5of FIG. 1;

FIG. 6 is a transverse section taken on line 6--6 of FIG. 1 and showingthe oil spray;

FIG. 7 is a perspective view of a baked confection disc; and

FIG. 8 is a perspective view of the formed taco-like shell.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The concepts of the invention are directed to processing a baked disc ofsugar-based confection material, shown at 1 in FIG. 7, into ataco-shaped shell shown at 2 in FIG. 8 and which is suitable for fillingwith ice cream or the like.

FIG. 1 shows a discharge station 3 for a disc baking machine of anysuitable type, not shown, and which feeds into a disc pick-up station 4.The disc is then passed to a forming station 5 wherein it is formed intoa shell, and then moved along conveyors 6, 6a for further processingbefore discharge.

The device includes a frame 7 on which is mounted a plurality of rollers8 over which are trained a narrow flat endless belt 9 which extendsalong conveyor 6. Belt 9 has a friction surface thereon and is driven bya drive roller 10 which is connected to a motor 11 through a series ofsprockets 12-15 and chains 16-18. Belt 9 extends from pick-up station 4to the discharge end of conveyor 6, with its lower flight adapted toengage the baked confection.

Referring to FIG. 2, the upstream end portion of belt 9 is trained overa clamping roller 19 which is adapted to clamp the belt successivelyagainst baked confection discs 1 placed on a table 20 forming part ofpick-up station 4. For this purpose, roller 19 is mounted to one end ofa lever arm 21, with the other arm end being pivotally mounted to frame7, as at 22. Lever arm 21 is biased downwardly by a spring 23 and isconnected to a centrally mounted plunger 24 which in turn is verticallyactuated by a solenoid 25 of any well-known type. Solenoid 25 iscontrolled by an automatic sequencing switch 26 to raise and lower arm21.

The baking machine discharge station 3 includes a table 27 swingableabout a vertical shaft 28 by any suitable camming mechanism. A discclamping means is disposed above table 27 and comprises a clamp 29disposed on the end of a plunger 30 which is actuated by a solenoid 31which is also controlled by sequencing switch 26.

The arrangement is such that clamp 29 grabs a disc 1 from the bakingmachine and table 27 is then swung around to the position shown toposition disc 1 at least partially over pick-up table 20. At the sametime, plunger 24 is in retracted position with the upstream end of belt9 spaced from table 20. Once a disc 1 is over table 20, plunger 30snappingly retracts to release clamp 29 from the disc and plunger 24simultaneously snappingly extends to cause belt 9 to grab the disc anddrivingly feed it to forming station 5. The position of plungers 24 and30 is then reversed so that the next disc 1 may be positioned and fedforwardly.

Referring to FIGS. 1, 3 and 4, forming station 5 comprises a formingwheel 32 which is mounted on a transverse shaft 33 and rotatably drivenfrom a motor 34 via a chain 35 and sprockets 36, 37. Forming wheel 32comprises a pair of axially spaced facing annular dish-shaped rollerelements 38 having inwardly inclinded side walls 39 and facing parallelbottom walls 40. A longitudinally extending rod 41 is disposed betweenelements 38 closely beneath shaft 33 and extends from table 20 toadjacent conveyor 6. The upper surface 42 of rod 41 is curved. Belt 9 ispositioned between shaft 33 and rod 41 and is coextensive with thelatter.

As belt 9 drives confection disc 1 into station 5 from station 4, thehot baked, relatively soft disc engages rotating walls 39 and 40 and islap folded so that it drops in hanging relationship onto rod 41, asshown in FIG. 4, now assuming the taco shell shape of FIG. 8 having twodownwardly hanging legs 43 joined by a folded portion 44.

Shell 2 is now driven by belt 9 into conveyor 6. Referring to FIGS. 1and 5, conveyor 6 includes a smooth elongated longitudinally extendinghollow shell support rail 45 which is fixedly mounted to frame 7 and iscoextensive with and disposed closely beneath belt 9. Rail 45 commencesadjacent the downstream end of rod 41 and is provided with a curvedupper surface 46 which approximates the inner curvature of foldedportion 44 of shell 2.

Channel means are provided to receive the downwardly hanging legs 43 ofshell 2. The inner channel wells are defined by the outer faces 47 of asupport device comprising a plurality of stacked tubes 48 fixedlymounted to frame 7 beneath rail 45. The outer channels walls are definedby the inner faces 49 of a pair of spaced parallel plates 50. Plates 50are generally parallel to faces 47 and are mounted for adjustmenttransversely of the conveyor, as by bolts 51 welded to the plates andmounted to upstanding walls of frame 7 by nuts 52 threaded thereon. Theadjustment provides a means to limit spreading of shell legs 43 to adesired spacing during conveying so that the width of shell 2 isprecisely controlled. This is important to enable the shells tosubsequently be properly fit into forms at the time of later filling.

When shells 2 enter conveyor 6, they are frictionally slid down rail 45by the lower flight of belt 9, which is biased toward the rail by springloading of rollers 8, as at 53. Shells 2 themselves are formed to assistin the friction driving of belt 9 and in the free sliding along rail 45.For this purpose, and as best shown in FIG. 8, the outer face 54 ofshell 2 is provided with an uneven friction surface such as bywaffeling, for engagement by belt 9, while the inner face 55 whichengages rail 45 is smooth.

Depending upon the length of the conveyor, it may be desirable toprovide an assist to the cooling of the hot baked shells as they traveltherealong, and not rely solely on the ambient air. Therefore, and inthe present embodiment, rail 45 and tubes 48 are connected through pipes56 to a suitable pressurized source of cooling fluid such as water whichflows through the rail and tubes and serves to cool the shells.

Furthermore, when shells 2 are to be filled with ice cream or othermaterial having a high moisture content, it is desirable to treat theshells so that they will stay crisp and not permit moisture tosignificantly penetrate into their interiors. For this purpose, theshells are treated with an oil spray. In the present embodiment, andreferring to FIGS. 1 and 6, the spray is provided at a second conveyorsection 6a which is downstream of and forms an extension to conveyorsection 6. At the discharge of conveyor 6, shells 2 slide off rail 45and down a ramp or slide 57 and will hangingly fall onto traveling chain17 which then carries them through a hood 58. A plurality of spraynozzles 59 are disposed within hood 58 and positioned to spray oil ontoboth the exterior and the interior of shells 2 to saturate them and makethem generally impervious to moisture. Nozzles 59 are supplied withpressurized oil from any suitable well-known source.

Shells 2 may then be discharged from conveyor section 6a, such as onto afurther slide 60 and hence to a discharge conveyor 61.

It has been found that the lower flight of belt 9 of conveyor 6 tends toundesirably stretch due to its being subjected to direct contact withthe hot baked shells 2. Such stretching may cause belt 9 to come loosefrom its guide rollers 8, especially on the return flight. Means aretherefore provided to cool the upper or return flight of belt 9 so thatit shrinks back to its normal shape. In the present embodiment, and asshown in FIG. 1, a nozzle 62 is mounted adjacent drive roller 10 and isadapted to discharge cold air onto belt 9. Nozzle 62 may be suppliedwith said air from any suitable well-known source.

Various modes of carrying out the invention are contemplated as beingwithin the scope of the following claims particularly pointing out anddistinctly claiming the subject matter which is regarded as theinvention.

We claim:
 1. A method of forming and conveying hot baked shells for usein confections and with said shells being initially soft and of discshape, comprising the steps of:(a) initially picking up said discs insuccession from a baking means and feeding said discs in a longitudinaldirection, (b) then forming said fed discs into lap folded taco-shapedshells having generally parallel spaced legs joined by a folded portion,(c) then feeding said formed shells onto an elongated fixed conveyorrail so that said shells hang therefrom, (d) then frictionally engagingand sliding said hanging shells progressively along said fixed railtoward a discharge point, (e) and supplying cooling fluid to theinterior of said rail as said shells slide therealong to thereby coolsaid shells.
 2. A method of forming and conveying hot baked shells foruse in confections and with said shells being initially soft and of discshape, comprising the steps of:(a) initially picking up said discs insuccession from a baking means and feeding said discs in a longitudinaldirection, (b) then forming said fed discs into lap folded taco-shapedshells having generally parallel spaced legs joined by a folded portion,(c) then feeding said formed shells onto an elongated fixed conveyorrail so that said shells hang therefrom, (d) then frictionally engagingand sliding said hanging shells progressively along said fixed railtoward a discharge point, (e) and spraying said shells with saturatingoil as they slide along said rail to make said shells impervious tomoisture.
 3. A method of forming and conveying hot baked shells for usein confections and with said shells being initially soft and of discshape, comprising the steps of:(a) initially picking up said discs insuccession from a baking means and feeding said discs in a longitudinaldirection, (b) then forming said fed discs into lap folded taco-shapedshells having generally parallel spaced legs joined by a folded portion,(c) then feeding said formed shells onto an elongated fixed conveyorrail so that said shells hang therefrom, (d) and then frictionallyengaging and sliding said hanging shells progressively along said fixedrail toward a discharge point, (e) said shells being frictionallyengaged and slid by an endless belt means which becomes heated uponcontact with said shells, (f) and the further step of cooling saidheated belt means.
 4. A method of forming and conveying hot baked shellsfor use in confections and with said shells being initially soft and ofdisc shape, comprising the steps of:(a) initially picking up said discsin succession from a baking means and feeding said discs in alongitudinal direction, (b) then forming said fed discs into lap foldedtaco-shaped shells having generally parallel spaced legs joined by afoled portion, (c) then feeding said formed shells onto an elongatedfixed conveyor rail so that said shells hang therefrom, (d) frictionallyengaging and slidingly driving said hanging shells progressively alongsaid fixed rail toward a discharge point, (e) adjustably limiting thespace between the legs of said hanging shells as they are slidinglydriven along said rail, (f) supplying cooling fluid to the interior ofsaid rail as said shells are slidingly driven therealong to thereby coolsaid shells, (g) spraying said cooled shells with saturating oil as theyare slidingly driven along said rail to make said shells impervious tomoisture, (h) said shells being engaged and driven by an endless beltmeans which becomes heated upon contact with said shells, (i) andcooling said heated belt means.